BATTERY CELL THERMAL CONTROL

IN BATTERY ELECTRIC VEHICLE

PROJECT REPORT

Submitted by

PRADEEP S
SRIRAM SANJEEV D

VIGNESH R P

YASHIK SNEHAN Y

in partial fulfilment for the award of the

degree of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

SRI SHAKTHI INSTITUTE OF ENGINEERING AND TECHNOLOGY

AUTONOMOUS INSTITUTION, COIMBATORE 641062

ANNA UNIVERSITY: CHENNAI 600 025

MAY 2023
 BATTERY CELL THERMAL CONTROL
IN BATTERY ELECTRIC VEHICLE

PROJECT REPORT

Submitted by

PRADEEP S 714019114051
SRIRAM SANJEEV D 714019114070
VIGNESH R P 714019114084
YASHIK SNEHAN Y 714019114086

in partial fulfilment for the award of the

degree of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

SRI SHAKTHI INSTITUTE OF ENGINEERING AND TECHNOLOGY

AUTONOMOUS INSTITUTION, COIMBATORE 641062

ANNA UNIVERSITY: CHENNAI 600 025

MAY 2023
 BONAFIDE CERTIFICATE

Certified that this project report titled “ BATTERY CELL THERMAL

CONTROL IN BATTERY ELECTRIC VEHICLE ” is a bonafied work of

PRADEEP S (714019114051), SRIRAM SANJEEV D (714019114070),

VIGNESH RP (714019114084), YASHIK SNEHAN Y (714019114086), who

have carried out this project under my supervision.

Signature Signature

Dr. S. GNANASEKARAN., P.hD Dr. S. GNANASEKARAN., P.hD

HEAD OF THE DEPARTMENT PROJECT SUPERVISOR

Department of Mechanical Engineering Department of Mechanical

Engineering Sri Shakthi Institute of Engineering Sri Shakthi Institute of

Engineering and Technology and Technology

Coimbatore - 641 062 Coimbatore - 641 062

Submitted for project viva voce examination held on ………

INTERNAL EXAMINER EXTERNAL EXAMINER

 ABSTRACT

The growing popularity of battery electric vehicles (BEVs) has led to an

increased demand for effective battery cell thermal control to maintain
performance, extend battery life, and prevent safety issues. This research paper
provides an overview of the strategies for battery cell thermal control in BEVs,
including passive and active cooling methods, as well as temperature monitoring
and management systems. The challenges associated with battery cell thermal
management, such as the trade-off between cooling efficiency and added weight,
the impact of ambient temperature on battery cell performance, and the need for
intelligent thermal management systems, are also discussed. The paper reviews the
current state-of-the-art in battery cell thermal control and identifies areas for future
research and development.

Advanced cooling systems, such as liquid cooling, are proposed as a promising

approach to improve cooling efficiency while minimizing added weight. The flow
of the pump is controlled by the battery's feedback, and the coolant goes via a
convey to achieve temperature control. Compared to lead-acid or nickel-metal
hydride batteries, lithium-ion batteries offer better energy densities. Moreover, it is
far less expensive and doesn't need nickel or cobalt. Also, it is safer since it is more
stable. Each battery cell has a water cooling block installed specifically for more
effective cooling. When compared to the method of calculating the total battery
heat without any controller on any individual cells of the battery, thermal control
over the individual Lithium-ion battery cells via SOC estimation would be more
effective.

Keywords: Battery Electric Vehicles, Battery Cell Thermal Control, Liquid

Cooling, Intelligent Thermal Management, Sustainability

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 ACKNOWLEDGEMENT

We express our deep sense of gratitude to the Chairman

Dr.S.Thangavelu for his invaluable guidance and blessings in the project work.
We are tremendously thankful to the secretary Mr.T.Deepan, joint
secretary Mr.T.Sheelan and Principal Dr.A.R.Ravikumar,for his unwavering
support during the entire course of this project work.
We are grateful to the Head of our Department, as well as our project
guide, Dr.S.Gnanasekaran, who modeled us both technically and morally for
greater success, and for his constant encouragement and support throughout our
course, especially for the useful suggestions during the course of the project
period.
We are deeply indebted to our Coordinator, Department of Mechanical
Engineering, Dr.A.Arun Negemiya, who modeled us both technically and
morally for greater success.
We are also thankful to all the staff members of our department and
technicians for their valuable assistance.
Finally, we take this opportunity to extend our deep appreciation to our
family and friends, for what they meant to us during the crucial times of the
completion of our project into a successful one and we conclude our thanks to
God for providing better situations.

PRADEEP S
SRIRAM SANJEEV D
VIGNESH R P
YASHIK SNEHAN Y

ii
 TABLE OF CONTENTS

CHAPTER PAGE
CONTENTS
NO. NO.
ABSTRACT i
ACKNOWLEDGEMENT ii
TABLE OF CONTENTS iii
LIST OF FIGURES vii
LIST OF TABLES viii
1 INTRODUCTION 1
1.1 Explanation of Battery Management System 3
1.2 Battery State of Charge Estimation 3
1.3 Battery State of Health Estimation 3
Industry Trends in Battery Cell
1.4 4
Thermal Management Systems
Best Practices in Battery Cell Thermal
1.5 4
Management Systems
Case Study – Tesla Model S Thermal
1.6 5
Management System
Overview of Tesla Model S Thermal Management
1.6.1 6
System
1.6.2 Battery Pack Thermal Management 6
1.6.3 Cabin Thermal Management 6
1.6.4 Design 7
1.6.5 Operation 7
1.6.6 Performance 8

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 1.7 Definition of this Project 8
1.8 Objective of this Project 8
1.9 Scope of this Project 9
2 REVIEW OF LITERATURE 10
2.1 Battery Cell Thermal Management Systems 10
2.1.1 Study of Liquid Cooling 10
2.1.2 Study of Air Cooling 11
2.1.3 Study of Phase-Change Materials 11

2.1.4 Study of Thermoelectric Cooling 11

2.1.5 Study of Hybrid Cooling 11

2.2 Impact of Temperature on Battery Performance 12
2.2.1 Study of Temperature Affects Battery Capacity 12
2.2.2 Study of Temperature Affects Battery Life 12
2.2.3 Study of Temperature Affects Battery Safety 12
Study of Temperature Affects Battery Charging
2.2.4 13
and Discharging
2.3 Temperature Control Strategies 13
2.3.1 Study of Thermal Management Systems 13
2.3.2 Study of Thermal Interface Materials 13
2.3.3 Study of Battery Packaging 14
2.3.4 Study of Operating Conditions 14
2.3.5 Study of Battery Chemistry 14
3 METHODOLOGY 15
4 MATERIALS AND METHODS 17

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 4.1 Conceptual Design 17
Materials and Selection of Battery Cell Thermal
4.2 18
Control
4.2.1 Water Pump 18
4.2.2 Radiator 19
4.2.3 Temperature Sensor 20
4.2.4 Power Supply (12V Battery) 20
4.2.5 Water Cooling Block 21
4.2.6 Arduino Board 24
4.2.7 Frame Stand 25
4.2.8 Heating Plate (Mild Steel) 27
5 ARDUINO PROGRAMMING 28
6 IMPLEMENTING MATLAB 32
6.1 Steps Involved in MATLAB Simulation 32
6.1.1 Define the Battery Cell Geometry 32
6.1.2 Define the Thermal Properties of the Materials 32
6.1.3 Define the Boundary Conditions 32
6.1.4 Define the Heat Generation Rate 32
6.1.5 Set up the Heat Transfer Equations 33
6.1.6 Run the Simulation 33
6.1.7 Analyze the Results 33
6.2 Example MATLAB Code 33
7 EXPERIMENTAL PROCEDURE 38
7.1 Block Diagram 38
7.2 Working in Steps 39

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8 RESULT & DISCUSSION 41
8.1 Temperature Variation in Water Cooling Block 42
8.2 Temperature Difference when Cycle is ON 43
8.3 Temperature Difference when Cycle is OFF 44
8.4 No. of Cycles vs Depth of Discharge Temperature 45
9 COST OF ESTIMATION 47
9.1 Product Bills 48
10 APPLICATIONS 52
10.1 Electric Vehicles 52
10.2 Hybrid Electric Vehicles 52
10.3 Renewable Energy Storage 52
10.4 Portable Electronic Devices 53
11 SUMMARY & CONCLUSION 54
11.1 Summary 54
11.2 Benefits of the Project 54
11.3 Learning from the Project 55
11.4 Achievements of the Project 55
11.5 Safety Standards of BMS 55
11.6 Conclusions 56
REFERENCES 57

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 LIST OF FIGURES

FIGURE NO. DESCRIPTION PAGE NO.

1.1 Design of Tesla Model S 7
4.1 Conceptual Design 17
4.2 Water Pump 19
4.3 Temperature Sensor 20
4.4 Water Cooling Block 22
4.5 Design of Water Cooling Block 23
4.6 Arduino Board MEGA 2560 R3 24
4.7 Frame Stand 25
4.8 Design of Frame Stand 26
7.1 Block Diagram 38
8.1 Temperature Variation in Water Cooling Block 42
8.2 Temperature Difference when Cycle is ON 43
8.3 Temperature Difference when Cycle is OFF 44
8.4 No. of Cycles vs Depth of Discharge Temperature 45
9.1 Invoice of Water Cooling Block 48
9.2 Invoice of Temperature Sensor 49
9.3 Invoice of Water Pump 50
9.4 Invoice of Arduino Components 51

vii
 LIST OF TABLE

TABLE NO. DESCRIPTION PAGE NO.

1 List of Electric Vehicle Companies 5

2 Cost of Estimation 47

viii
 CHAPTER 1

INTRODUCTION

Thermal management systems for battery cells in BEVs typically involve either air
or liquid cooling systems, or a combination of both. The effectiveness of these
systems depends on various factors such as the battery pack design, ambient
temperature, driving conditions, and the specific cooling system used.

Battery electric vehicles (BEVs) are gaining in popularity as a clean, sustainable

mode of transportation. Unlike internal combustion engines, BEVs produce zero
emissions and are more energy-efficient, making them an attractive option for
consumers and policymakers alike. However, BEVs also come with their own set
of challenges, including battery cell thermal management.

Battery cell thermal management is critical to the performance and safety of BEVs.
Battery cells operate best within a specific temperature range, and failure to
maintain this range can cause reduced performance, shortened lifespan, and even
thermal runaway, which can result in fires or explosions. In this report, we will
explore the various strategies for battery cell thermal management in BEVs, as
well as the challenges associated with these strategies.

Passive cooling is the simplest and most cost-effective form of battery cell thermal
management. This method relies on the design of the battery pack to dissipate heat
naturally, using materials such as aluminum or copper to conduct heat away from
the cells. Passive cooling can be effective in mild climates or low-demand
situations, but it has limitations in extreme temperatures or high-demand
conditions, such as fast charging or high-speed driving.

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Active cooling is a more complex and expensive form of battery cell thermal
management that uses cooling systems to actively regulate the temperature of the
battery pack. There are several types of active cooling systems, including air
cooling, liquid cooling, and phase change materials.

Air cooling is the most common form of active cooling and uses fans or blowers to
circulate air through the battery pack. While air cooling is effective at removing
heat from the battery cells, it can be limited in its ability to cool the cells quickly
enough during high-demand situations.

Liquid cooling is a more advanced form of active cooling that uses a liquid
coolant, such as water or glycol, to absorb heat from the battery cells. Liquid
cooling is more efficient than air cooling and can be customized to meet the
specific cooling needs of the battery cells. However, liquid cooling systems are
more complex and can add weight and cost to the vehicle.

Phase change materials (PCMs) are another form of active cooling that uses
materials that can absorb and release heat as they change phase. PCMs can be
integrated into the battery pack to help regulate temperature and reduce the need
for active cooling systems.

This report discusses the various aspects of battery cell thermal control in battery
electric vehicles. The report starts with an overview of battery chemistries and their
heat generation mechanisms. It then describes the effect of temperature on battery
life and performance. The different thermal management techniques such as liquid
cooling, air cooling, and phase change material cooling are also discussed in detail.

2
1.1 Explanation of Battery Management System
A Battery Management System (BMS) is an electronic system that manages and
monitors the performance of a rechargeable battery, ensuring that it operates safely
and efficiently. A BMS typically monitors the state of charge, state of health,
temperature, and voltage of a battery, and uses this information to optimize
charging and discharging, prevent overcharging or over-discharging, and prolong
the battery's lifespan.

A typical BMS includes several components, including sensors, control circuits,

and communication interfaces. The sensors measure various parameters of the
battery, such as voltage, current, and temperature, while the control circuit
processes this data and uses it to control the battery's charging and discharging
process. The communication interfaces allow the BMS to communicate with other
devices, such as a battery charger or a vehicle's onboard computer.

1.2 Battery State of Charge Estimation

Battery state of charge (SOC) estimation is a critical task in many applications,

such as electric vehicles, renewable energy systems, and portable devices.
Accurately estimating the SOC of a battery can help optimize its performance,
extend its life, and prevent overcharging or over-discharging, which can cause
damage to the battery.

1.3 Battery State of Health Estimation

Battery state of health (SOH) estimation is another critical task in many
applications that rely on batteries, such as electric vehicles and renewable energy
systems. The SOH represents the battery's overall condition and its ability to hold a
charge compared to its original capacity. Accurately estimating the SOH can help

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prevent unexpected battery failures, optimize performance, and extend the battery's
lifespan.

1.4 Industry Trends in Battery Cell Thermal Management Systems

The electric vehicle industry has been rapidly growing in recent years, and with it,
the demand for battery cell thermal management systems. One of the primary
industry trends is the shift towards liquid cooling systems. Liquid cooling systems
are generally more effective than air cooling systems as they can remove heat more
efficiently. They can also be designed to be more compact, which is beneficial for
electric vehicles with limited space.

Another industry trend is the development of intelligent thermal management

systems. These systems use sensors and data analysis to regulate the temperature of
the battery cells more accurately. This technology can optimize the performance
and extend the life of battery cells by maintaining them within a safe and efficient
temperature range.

1.5 Best Practices in Battery Cell Thermal Management Systems

The following are some best practices for battery cell thermal management
systems:

 Use liquid cooling systems for optimal efficiency and effectiveness.

 Implement intelligent thermal management systems that use sensors and data
analysis to regulate temperature more accurately.
 Incorporate phase change materials (PCMs) into the design of the thermal
management system to reduce the need for additional cooling or heating.

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 Design the thermal management system to be compact and lightweight to
reduce the overall weight and size of the electric vehicle.
 Use high-quality components and materials to ensure the durability and
longevity of the thermal management system.
 Perform regular maintenance and inspections to ensure the system is
functioning correctly and efficiently.
 Ensure that the thermal management system is integrated into the overall design
of the electric vehicle to maximize its effectiveness and efficiency.

Table 1 - List of Electric Vehicle Companies

 Mercedes-Benz  Porsche

 Tesla  Nissan

 General Motors  Hyundai

 Ford  Kia

 Volkswagen  Audi

 Lucid Motors  BYD

1.6 Case Study - Tesla Model S Thermal Management System

Tesla Model S is a luxury all-electric vehicle that is known for its impressive
driving range and performance. One of the key features that contribute to its
success is its thermal management system, which effectively manages the
temperature of its battery pack, motor, and cabin. This case study explores the
thermal management system of the Tesla Model S and evaluates its effectiveness
in mitigating battery cell overheating.

5
1.6.1 Overview of Tesla Model S Thermal Management System

The Tesla Model S uses a liquid cooling system to manage the temperature of its
battery pack, motor, and cabin. The system consists of a series of pipes and
radiators that circulate coolant through the various components of the vehicle. The
coolant is a mixture of water and ethylene glycol, which has a higher boiling point
and lower freezing point than water, making it more effective at managing
temperature extremes.

1.6.2 Battery Pack Thermal Management

The battery pack in the Tesla Model S is located underneath the vehicle and
consists of thousands of lithium-ion cells. These cells generate a significant
amount of heat during operation, and it is essential to manage their temperature to
ensure their safe and efficient operation. The battery pack in the Tesla Model S
uses a liquid cooling system to maintain a consistent temperature range. The
coolant circulates through the battery pack, absorbing heat from the cells and
transferring it to a heat exchanger located at the front of the vehicle. The heat
exchanger dissipates the heat to the ambient air.

1.6.3 Cabin Thermal Management

The cabin of the Tesla Model S is equipped with a sophisticated thermal

management system that maintains a comfortable temperature for passengers. The
system includes a heat pump that uses the energy from the battery pack to heat or
cool the cabin, depending on the desired temperature. The system also includes a
series of vents and fans that circulate the air throughout the cabin.

6
1.6.4 Design

The thermal management system in the Tesla Model S is designed to regulate the
temperature of the battery pack and other critical components to ensure optimal
performance and longevity. The system consists of two separate liquid coolant
loops, one for the battery pack and one for the power electronics and electric
motor. The coolant loops are connected to a series of heat exchangers and fans that
help to dissipate heat generated by the components.

Fig. 1.1 Design of Tesla Model S

1.6.5 Operation

The thermal management system in the Tesla Model S operates in a closed-loop

system, where the coolant is circulated through the components and heat
exchangers and then returned to the reservoir for reuse. The system is designed to
maintain the temperature of the battery pack within a specific range, typically
between 15°C and 35°C, depending on the operating conditions and the state of
charge of the battery.

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1.6.6 Performance

The thermal management system in the Tesla Model S has been shown to be
highly effective at maintaining the temperature of the battery pack and other
components within the desired range. This has been demonstrated in a variety of
operating conditions, including extreme heat and cold, as well as during high-speed
driving and heavy use of the electric motor.

1.7 Definition of this Project

Battery cell thermal control in a BEV refers to the various methods and systems
used to regulate and maintain the temperature of the battery cells within a safe and
optimal range. This involves the use of thermal management systems that can
either cool or heat the battery cells as required to maintain their temperature within
the desired range. Effective battery cell thermal control is critical for maximizing
the performance and lifespan of the battery cells, as well as ensuring their safety.

1.8 Objective of this Project

The objective of this project is to provide a comprehensive analysis of battery cell

thermal control in a BEV. The project aims to review the current literature on
battery cell thermal management systems and their impact on battery performance
and safety. Additionally, the project aims to examine industry trends and best
practices in battery cell thermal control, and to present a case study on the Tesla
Model S thermal management system. The project also aims to discuss potential
future developments in battery cell thermal control systems and their impact on the
BEV industry. The growing trend towards electric vehicles (EVs) has prompted
manufacturers to pay more attention to the thermal management of battery cells in

8
these vehicles. One of the most significant factors that can affect the performance
and lifespan of battery cells is their temperature.

1.9 Scope of this Project

The scope of this project includes a review of the current literature on battery cell
thermal control, including the various systems and methods used to regulate and
maintain battery cell temperature in a BEV. The project will also examine the
impact of temperature on battery performance and safety, as well as different
temperature control strategies. Additionally, the project will present a case study
on the Tesla Model S thermal management system and discuss industry trends and
best practices in battery cell thermal control. Finally, the project will discuss
potential future developments in battery cell thermal control systems and their
impact on the BEV industry.

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 CHAPTER 2
REVIEW OF LITERATURE

The literature review provides an overview of the current state of research on

battery cell thermal control in BEVs. The review highlights the importance of
thermal management in BEVs and presents various thermal management
strategies, including active and passive cooling. The review also examines the
impact of ambient temperature, vehicle design, and driving conditions on battery
cell temperature and the effectiveness of various thermal management strategies in
mitigating overheating.

2.1 Battery Cell Thermal Management Systems

Battery cell thermal management systems are used to maintain the temperature of
the battery within a safe and optimal range to improve its performance, safety, and
durability. Here is a brief literature review of some of the most commonly used
thermal management systems for batteries:

2.1.1 Study of Liquid Cooling

Li et al. (2018) has found that using a liquid cooling system to maintain the
temperature of Li-ion batteries at 25°C improved their capacity retention by up to
25%. Liquid cooling systems typically use a coolant, such as water or a glycol-
based solution, to absorb the heat generated by the battery and transfer it away
from the battery to a heat exchanger. Liquid cooling is a common thermal
management system for high-power and high-capacity batteries.

1
2.1.2 Study of Air Cooling
Hu et al. (2016) analyzed that using an air cooling system to maintain the
temperature of Li-ion batteries at 30°C improved their capacity retention by up to
14%. Air cooling systems typically use a fan or a heat sink to circulate air around
the battery and dissipate heat. Air cooling is a simpler and less expensive thermal
management system than liquid cooling, but it is not as effective in dissipating heat
from the battery.

2.1.3 Study of Phase-Change Materials

Zuo et al. (2016) studied that using a phase-change material to improve the thermal
contact between a Li-ion battery and a cooling system reduced the battery's
temperature rise during high-rate discharge by up to 25%. Phase-change materials,
such as paraffin wax or fatty acids, are used as thermal storage materials to absorb
and release heat as they change phase from solid to liquid or vice versa.

2.1.4 Study of Thermoelectric Cooling

Wang et al. (2018) carried out using a thermoelectric cooling system to maintain
the temperature of Li-ion batteries at 25°C improved their capacity retention by up
to 8%. Thermoelectric cooling systems are typically more expensive and less
efficient than liquid or air cooling systems. Thermoelectric cooling is a solid-state
cooling technology that uses the Peltier effect to transfer heat from one side of a
thermoelectric module to the other side.

2.1.5 Study of Hybrid Cooling

Kim et al. (2019) illustrated that using a hybrid cooling system that combines a
phase-change material and an air cooling system improved the thermal
management of Li-ion batteries and extended their cycle life. Hybrid cooling

1
systems combine two or more thermal management technologies, such as liquid
and air cooling or phase-change materials and thermoelectric cooling, to improve
the overall thermal performance of the battery.

2.2 Impact of Temperature on Battery Performance

The impact of temperature on battery performance is significant and can affect the
capacity, life, safety, and charging/discharging rates of batteries. Batteries are
electrochemical devices that rely on chemical reactions to produce and store
energy, and these reactions are sensitive to temperature changes.

2.2.1 Study of Temperature Affects Battery Capacity

Xu et al. (2017) explained that Li-ion batteries operated at 25°C had a capacity
retention of 82% after 200 cycles, while batteries operated at 45°C had a capacity
retention of only 68%. On the other hand, a study by Lu et al. (2014) found that Li-
ion batteries stored at -20°C had an increased capacity retention of up to 20%.
High temperatures can decrease battery capacity, while low temperatures can
increase capacity.

2.2.2 Study of Temperature Affects Battery Life

Shin et al. (2013) studied that operating Li-ion batteries at 60°C reduced their life
by up to 60%. On the other hand, a study by Zheng et al. (2015) found that storing
Li-ion batteries at -20°C increased their life by up to 50%. High temperatures can
decrease battery life, while low temperatures can increase life.

2.2.3 Study of Temperature Affects Battery Safety

Zhang et al. (2019) described the probability of thermal runaway in Li-ion batteries
increased significantly at temperatures above 60°C. In contrast, a study by Dong et

1
al. (2017) found that storing Li-ion batteries at -20°C reduced the risk of thermal
runaway. High temperatures can increase the risk of thermal runaway, while low
temperatures can decrease this risk.

2.2.4 Study of Temperature Affects Battery Charging and Discharging

Chen et al. (2016) demonstrated that charging Li-ion batteries at 60°C increased
their degradation rate by up to 3 times, while a study by Lee et al. (2014) found
that charging Li-ion batteries at -10°C reduced their degradation rate by up to 50%.
High temperatures can increase the rate of battery degradation during charging and
discharging, while low temperatures can decrease this rate.

2.3 Temperature Control Strategies

There are several temperature control strategies that have been proposed and tested
to improve battery performance. Here is a brief literature review of some of the
most commonly used strategies:

2.3.1 Study of Thermal Management Systems

Li et al. (2018) found that using a liquid cooling system to maintain the
temperature of Li-ion batteries at 25°C improved their capacity retention by up to
25%. One of the most effective ways to control battery temperature is through
thermal management systems, which use cooling or heating elements to maintain
the battery temperature within a specific range.

2.3.2 Study of Thermal Interface Materials

Zuo et al. (2016) studied that using a phase-change material to improve the thermal
contact between a Li-ion battery and a cooling system reduced the battery's
temperature rise during high-rate discharge by up to 25%. Thermal interface

1
materials, such as thermal greases, thermal pads, and phase-change materials, are
used to improve the thermal contact between the battery and the cooling or heating
elements.

2.3.3 Study of Battery Packaging

Song et al. (2016) analyzed that using a graphene oxide coating on the aluminum
foil of a Li-ion battery improved its thermal stability and reduced its temperature
rise during high-rate discharge by up to 30%. The design and materials of battery
packaging can also affect the battery temperature.

2.3.4 Study of Operating Conditions

Zhang et al. (2021) illustrated that reducing the discharge rate of a Li-ion battery
from 1C to 0.2C reduced its temperature rise by up to 20%. Adjusting the
operating conditions of the battery, such as the charge and discharge rates, can also
affect the battery temperature.

2.3.5 Study of Battery Chemistry

Chen et al. (2021) proved that using a solid-state electrolyte in a Li-ion battery
improved its thermal stability and reduced the risk of thermal runaway. Improving
the battery chemistry, such as using solid-state electrolytes or new electrode
materials, can also help to reduce the temperature sensitivity of batteries.

1
 CHAPTER 3
METHODOLOGY

The methodology for implementing a thermal control system for battery cells using
Arduino can be divided into the following steps:

 Battery cell and enclosure selection: Determine the number of battery cells
required for the application and select an appropriate enclosure to house the
battery cells.

 Temperature sensor selection: Choose temperature sensors that are

compatible with the Arduino board and have suitable accuracy and precision for
the desired level of temperature monitoring.

 Arduino board selection: Select an Arduino board that has sufficient

processing power and suitable input/output (I/O) capabilities for the
temperature sensor and cooling or heating device connections.

 Cooling or heating device selection: Choose a cooling or heating device that is

compatible with the Arduino board and has sufficient cooling or heating
capacity for the application.

 Circuit design: Design the circuitry to connect the temperature sensors,

cooling or heating device, and power supply to the Arduino board. The circuit
should be designed to meet the application's voltage and current requirements.

1
 Programming: Write the firmware for the Arduino board to read the
temperature sensor data and control the cooling or heating device. The firmware
should include temperature setpoints, control logic, and error handling.

 Assembly and testing: Assemble the thermal control system and test its
operation using a suitable power supply and test setup. The system should be
tested under varying temperature conditions to ensure that it operates as
expected.

 Optimization: Monitor the system's performance and temperature data to

optimize the thermal control system's parameters, such as temperature setpoints
and cooling or heating device activation thresholds. The system can also be
optimized to minimize power consumption and improve battery lifespan.

 Integration: Integrate the thermal control system into the larger battery
management system and validate its operation under actual operating
conditions.

In summary, the methodology for implementing a thermal control system for

battery cells using Arduino involves selecting the appropriate battery cells,
temperature sensors, Arduino board, and cooling or heating device, designing the
circuitry and programming the Arduino board, assembling and testing the system,
optimizing its performance, and integrating it into the larger battery management
system.

1
 CHAPTER 4
MATERIALS AND METHODS

In this chapter, the substances or materials used in the creation of a work of art, as
well as any production or manufacturing techniques, processes, or methods
incorporated in its fabrication. This information includes a description of the
materials used to create the work and how they were put together.

4.1 Conceptual Design

The conceptual design of the battery cell thermal control setup is shown in Fig. 4.1

Fig. 4.1 Conceptual Design

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4.2 Materials and Selection of Battery Cell Thermal Control
The major components that are used in the manufacturing of this project are as
follows,

i. Water Pump
ii. Radiator
iii. Temperature Sensor
iv. 12v Battery
v. Water Cooling Block
vi. Arduino Board

4.2.1 Water Pump

A 12V water pump is a type of pump that is designed to run on a 12-volt DC

power source, the type we used in this work is added as an image below in figure
4.2. These pumps are commonly used in various applications, such as for pumping
water from a well or a water tank, for circulating water in a cooling system, or for
creating a water fountain or waterfall.

 Flow Rate: 6 Litres Per Min

 Inbuilt Thermal Overload Protector, Long life, self priming
 Input and Output pipe size : 8mm or 8.5mm
 The red wire is positive and green wire is negative.

1
 Fig. 4.2 Water Pump

4.2.2 Radiator

A radiator is a heat exchanger that is used to transfer thermal energy from one
medium to another for the purpose of cooling or heating. In a heating system, a
radiator is typically used to transfer heat from hot water or steam to the air in a
room, thereby increasing the temperature of the room. Radiators are commonly
found in homes, buildings, and vehicles, and can be made from a variety of
materials such as cast iron, steel, or aluminum. They typically consist of a series of
interconnected pipes or channels that allow a heating fluid to flow through and
transfer heat to the surrounding environment. Radiators can be an effective and
efficient way to heat a space, especially in colder climates.

1
4.2.3 Temperature Sensor

A temperature sensor is an electronic device that measures the temperature of an

object or environment and converts it into an electrical signal that can be read by a
computer or other electronic device where the type of sensor we used is attached
below in figure 4.3. There are many types of temperature sensors, including
thermocouples, resistance temperature detectors (RTDs), thermistors, and infrared
sensors.

Fig. 4.3 Temperature Sensor

Temperature sensor installation: Temperature sensors are placed inside the

battery cell enclosure to monitor the temperature of the battery cells. The number
of temperature sensors depends on the size of the battery cell enclosure and the
desired level of temperature monitoring.

4.2.4 Power Supply (12V Battery)

A 12V battery is a rechargeable battery that can provide a steady voltage of 12

volts. It is commonly used as a power source for various applications, such as
powering electronic devices, portable lighting, or even as a backup power source.

2
The 12V battery can be made of different types of cells, such as lead-acid, nickel-
cadmium, or lithium-ion. Lead-acid batteries are commonly used in automotive
and marine applications, while lithium-ion batteries are used in portable devices
like smartphones and laptops.

The capacity of a 12V battery is measured in ampere-hours (Ah), which indicates

the amount of charge the battery can deliver in one hour. For example, a 12V
battery with a capacity of 50Ah can deliver a current of 5 amps for 10 hours or 1
amp for 50 hours. To use a 12V battery as a power supply, it needs to be connected
to a voltage regulator to provide a stable output voltage suitable for the intended
application. The voltage regulator regulates the voltage to the required level and
also filters out any electrical noise or fluctuations. When using a 12V battery as a
power supply, it's essential to ensure that the battery is properly charged and
maintained to prevent any damage or safety hazards. Regular maintenance includes
checking the battery's electrolyte level (for lead-acid batteries), cleaning the
terminals, and ensuring proper ventilation during charging.

4.2.5 Water Cooling Block

A water cooling block, also known as a water block, is a specialized device used in
liquid cooling systems for electronic components, such as CPUs and GPUs. Its
purpose is to transfer heat from the component to a liquid coolant, typically water,
which then flows through the system and carries the heat away from the
component. The water cooling block is made of a highly conductive material, such
as copper or aluminum, and is designed to fit onto the specific electronic
component it is meant to cool shown in figure 4.4. The block is typically machined

2
with micro channels or fins to increase its surface area, which allows for greater
heat transfer from the component to the coolant.

The coolant is typically circulated through the system via a pump and tubing, and
is often cooled by a radiator with fans or other cooling methods. As the coolant
passes through the water block, it absorbs the heat from the component and carries
it away, helping to maintain optimal temperatures for the electronic device. There
are many different types of water cooling blocks available, with various designs
and materials, and it's important to choose one that is compatible with your specific
component and system configuration. When selecting a water cooling block,
factors such as size, compatibility, and cooling performance should all be taken
into consideration to ensure optimal cooling for your electronic device.

Fig. 4.4 Water Cooling

Block Features of Water Block:

 Exclusive water-cooling heads, liquid-cooled water plates, and water-cooled

exchangers for semiconductor refrigeration fins.
 Completely consistent with the cooling film, and can be used for small
productions such as mobile phone and computer heat dissipation, cold transfer,

2
cold water formation, etc.

2
 Suitable for industrial inverter drive, laser head cooling, industrial control
cabinet cooling, etc.
 Can be used for heat dissipation, cold transfer, good-quality aluminium material
possesses good strength, good corrosion resistance.
 Made after double-sided polishing surface treatment, exquisite and smooth
without burrs.

Design of Water Cooling Block

The water cooling block's dimensions are shown in Figure 4.5; Creo 9.0 software
was the tool used to design.

Fig. 4.5 Design of Water Cooling Block

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Specification of Water Block:
Item Type: Water Cooling Block
Material: Aluminium
Purpose: Heat dissipation, cold transfer
Size: 40 x 200mm

4.2.6 Arduino Board

An Arduino board is a microcontroller-based development board that is designed

to be used by artists, designers, hobbyists, and anyone interested in creating
interactive electronic projects.

Fig. 4.6 Arduino Board MEGA 2560 R3

Arduino boards are usually equipped with digital input/output pins, analog input
pins, serial communication interfaces, power supply components, and other
components that enable users to connect and control various electronic devices.
They also come with a variety of pre-built libraries and functions that make it easy
to write and upload code to the board. Arduino boards are open-source and can be

2
programmed using the Arduino Integrated Development Environment (IDE), a free
software tool that allows users to write and upload code to the board using a USB
connection.

Arduino Board Setup: The Arduino board is connected to the temperature

sensors, relay module, and cooling or heating device. The Arduino board's
firmware is programmed to read the temperature sensor data and control the
cooling or heating device through the relay or motor driver module.

4.2.7 Frame Stand

This is constructed of mild steel which shown in Figure 4.7. The entire assembly is
installed to the frame structure in a way that works. For correct bearing alignment
during assembly, bearing sizes and open bores were bored in one session. Our team
members handle the welding portion; arc welding is the sort of welding employed
for this frame construction. A cross member with a 3mm diameter is additionally
apparent in the top view of the frame. It is comprised of mild steel. In order to
avoid sharp edges in the frame, all of the frame's edges have been properly
grinded with the use of a grinding machine.

Fig. 4.7 Frame Stand

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Design of Frame Stand

Figure 4.8 displays the frame stand's dimensions, which were designed using Creo
9.0 software.

Fig. 4.8 Design of Frame Stand

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4.2.8 Heating Plate (Mild Steel)

A heating plate made of mild steel can be used for various heating applications
such as cooking, soldering, brazing, and welding. Mild steel is a popular choice for
heating plates because of its excellent thermal conductivity and durability.

However, it is important to note that mild steel can warp or deform when exposed
to high temperatures for an extended period of time. To avoid this, it is
recommended to use a thick plate that can handle the heat and distribute it evenly
across the surface.

Additionally, mild steel can also corrode when exposed to moisture and oxygen, so
it is important to keep the heating plate clean and dry when not in use. Regular
maintenance and proper storage can help prolong the life of the heating plate.

2
 CHAPTER 5
ARDUINO PROGRAMMING

Here is an Arduino code that can be used to control the water pump flow based on
temperature readings from a temperature sensor:

// Include the OneWire and DallasTemperature libraries

#include <OneWire.h>

#include <DallasTemperature.h>

// Data wire is plugged into digital pin 2 on the Arduino

#define ONE_WIRE_BUS 2

// Setup a oneWire instance to communicate with any OneWire devices

OneWire oneWire(ONE_WIRE_BUS);

// Pass the oneWire reference to DallasTemperature library

DallasTemperature sensors(&oneWire);

// Pin connected to relay module for controlling the water pump

int relayPin = 3;

// Set the temperature threshold at which the pump will turn on

int temperatureThreshold = 50;

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void setup() {

// Start serial communication

Serial.begin(9600);

// Initialize the relay pin as an

output pinMode(relayPin,

OUTPUT);

// Start the temperature

sensor sensors.begin();

void loop() {

// Call sensors.requestTemperatures() to issue a temperature request and

// send the temperature reading to the serial monitor

sensors.requestTemperatures();

float temperature = sensors.getTempCByIndex(0);

Serial.print("Temperature: ");

Serial.print(temperature);

Serial.println("C");

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// If the temperature is above the threshold, turn on the water pump

3
 if (temperature >= temperatureThreshold) {

digitalWrite(relayPin, HIGH);

Serial.println("Water pump turned on");

// Otherwise, turn off the water

pump else

digitalWrite(relayPin, LOW);

Serial.println("Water pump turned

off");

// Wait for 1 second before taking the next temperature reading

delay(1000);

In this code, we first include the necessary libraries for using the OneWire protocol
to communicate with a DallasTemperature sensor and for controlling the relay
module. We then define the pin number for the relay module and set the
temperature threshold at which the pump will turn on.

3
In the setup function, we initialize the relay pin as an output and start the
temperature sensor.

In the
loop function, we first call to issue a
sensors.requestTemperatures
temperature request to the sensor and obtain the temperature reading. We then use
an i statement to check whether the temperature is above the threshold. If it is, we
turn on the water pump by setting the relay pin to HIGH, and if it is not, we turn
off the water pump by setting the relay pin to LOW. We also print the temperature
and pump status to the serial monitor for debugging purposes.

Finally, we add a
delay(100 statement to wait for 1 second before taking the next
temperature reading.

3
 CHAPTER 6
IMPLEMENTING MATLAB

6.1 Steps Involved in MATLAB Simulation

Here are the steps to perform a MATLAB simulation for battery cell thermal
control:

6.1.1 Define the Battery Cell Geometry

Create a 3D model of the battery cell in MATLAB, including the cell dimensions,
electrode thicknesses, and separator thickness.

6.1.2 Define the Thermal Properties of the Materials

Define the thermal conductivity, specific heat, and density of the cell components,
such as the electrode material, separator, and electrolyte. These values can be
obtained from material specifications or experimental measurements.

6.1.3 Define the Boundary Conditions

Define the initial and boundary conditions for the simulation, including the
ambient temperature, the temperature of the cooling system, and the initial
temperature of the battery cell.

6.1.4 Define the Heat Generation Rate

Define the heat generation rate within the cell, which is a function of the cell's
internal resistance and the current passing through the cell. This can be calculated
using MATLAB's built-in functions.

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6.1.5 Set up the Heat Transfer Equations
Use MATLAB's partial differential equation (PDE) solver to set up the heat
transfer equations for the battery cell, which includes the heat generation rate,
thermal conductivity, specific heat, and density.

6.1.6 Run the Simulation

Run the simulation using MATLAB's PDE solver and specify the output variables
to be analyzed, such as the temperature distribution within the cell.

6.1.7 Analyze the Results

Analyze the results of the simulation to understand the thermal behavior of the
battery cell during operation. This includes examining the temperature distribution
within the cell, as well as the temperature of individual components, such as the
electrodes and electrolyte. The analysis can be used to identify potential hot spots
within the cell and optimize the cell design to improve the thermal performance.

6.2 Example MATLAB Code

Here is an example MATLAB simulation code for battery cell thermal control in a
battery electric vehicle:

% Battery cell thermal control simulation

% Define the parameters for the battery cell

cellCapacity = 30; % Ah

cellVoltage = 3.7; % V

3
cellResistance = 0.05; % Ohm

cellMass = 1.2; % kg

% Define the parameters for the cooling

system coolantFlowRate = 0.05; % L/s

coolantSpecificHeat = 4186; % J/(kg*K)

coolantDensity = 1000; % kg/m^3

coolantTemperature = 25; % degC

coolantMass = 5; % kg

% Define the simulation time and time step

simulationTime = 3600; % s

timeStep = 1; % s

% Initialize the arrays for temperature and current

cellTemperature = zeros(simulationTime/timeStep, 1);

cellCurrent = zeros(simulationTime/timeStep, 1);

% Set the initial cell temperature and current

cellTemperature(1) = 25; % degC

cellCurrent(1) = 10; % A

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% Run the simulation

for i = 2:simulationTime/timeStep

% Calculate the heat generated by the cell

heatGeneration = cellCurrent(i-1)^2 * cellResistance;

% Calculate the heat transferred from the cell to the coolant

heatTransfer = coolantFlowRate * coolantDensity * coolantSpecificHeat

* (cellTemperature(i-1) - coolantTemperature);

% Calculate the temperature change of the cell and coolant

cellTemperatureChange = (heatGeneration - heatTransfer) / (cellMass *

cellSpecificHeat);

coolantTemperatureChange = heatTransfer / (coolantMass *

coolantSpecificHeat);

% Update the temperature and current values for the cell

cellTemperature(i) = cellTemperature(i-1) + cellTemperatureChange *

timeStep;

cellCurrent(i) = cellCurrent(i-1) + (rand() - 0.5) * 2; % Add some

random noise to the current for realism

% Update the coolant temperature

3
 coolantTemperature = coolantTemperature +
coolantTemperatureChange * timeStep;

end

% Plot the results

time = linspace(0, simulationTime, simulationTime/timeStep);

figure;

subplot(2,1,1);

plot(time, cellTemperature);

xlabel('Time (s)');

ylabel('Cell Temperature

(degC)'); subplot(2,1,2);

plot(time, cellCurrent);

xlabel('Time (s)');

ylabel('Cell Current (A)');

In this code, we first define the parameters for the battery cell, including its
capacity, voltage, resistance, and mass. We also define the parameters for the
cooling system, including the coolant flow rate, specific heat, density, and initial
temperature, as well as the coolant mass.

3
We then initialize the arrays for the cell temperature and current, and set the initial
values. In the for loop, we calculate the heat generated by the cell and the heat
transferred from the cell to the coolant, based on the previous temperature and
current values. We then calculate the temperature change of the cell and coolant,
and update the temperature and current values for the cell. We also add some
random noise to the current for realism. Finally, we update the coolant temperature
based on the heat transferred.

After running the simulation, we plot the results for the cell temperature and
current over time. Note that this is just a simple example of a Matlab simulation for
battery cell thermal control, and the actual implementation would be much more
complex and involve more parameters and models.

3
 CHAPTER 7
EXPERIMENTAL PROCEDURE

7.1 Block Diagram

Figure 7.1 represents the working procedure of battery cell thermal control system,
and its functions taken place while performing the task. Also mentioned about the
components used in this project.

Fig. 7.1 Block Diagram

4
7.2 Working in Steps

Step 1: Filling the water tank with coolant is the first stage in this functional
model.

Step 2: A water pulling component from the water tank has been implemented
using a 12V water pump.

Step 3: Coolant is pumped up from the tank and flows into a water cooling block.

Step 4: Where the heating Plate (Alternate to the Battery Cell) is placed on top of
the Water cooling block.

Step 5: Coolant flows in the inlet and comes out in a different outlet of the water
cooling block.

Step 6: A flow reducer valve is attached to the water cooling block's output,
reducing the coolant's flow (Water).

Step 7: To reduce the water's temperature, the water then enters the radiator.

Step 8: The water flows back into the water tank from the radiator. This procedure
has been carried out repeatedly.

Step 9: The power source for the water pump and the Arduino board has been
distributed using a 12V rechargeable battery.

Step 10: As the temperature rises (for example, to roughly 50°C), the signal from
the temperature sensor is transferred to the Arduino board.

4
Step 11: Between the Arduino board and the 12V battery lies a relay module. The
task is completed by the Arduino board after it gets the signal.

Step 12: When the temperature of the heating plate climbs over the predetermined
value, the Arduino is used to automatically manage the water pump flow without
any operator assistance.

4
 CHAPTER 8

RESULT & DISCUSSION

A crucial component of battery electric vehicle (BEV) design and operation is

battery cell heat regulation. In order to maximize performance, lengthen battery
life, and avoid safety risks, the thermal management system of a BEV makes sure
that the battery cells function within a specific temperature range.

Controlling the heat that is produced while charging and discharging is one of the
main difficulties in battery cell thermal management. Thermal runaway, which can
harm the battery and provide safety risks, can be brought on by the heat produced
while charging. On the other hand, a battery's performance and longevity may be
impacted by high-temperature discharge.

BEV producers often combine passive and active cooling technologies to

overcome these issues. Heat generated during charging is dissipated and heat loss
is prevented during operation using passive cooling solutions like heat sinks and
thermal insulation. Battery cell temperatures are kept within a certain range by
active cooling devices, such as liquid or air cooling.

Since liquid cooling systems provide effective heat transfer and better temperature
control than air cooling systems, they are frequently employed in high-
performance BEVs. A coolant is pumped through the battery pack in liquid cooling
systems to absorb heat produced during charging and discharging. The coolant is
then cycled through the battery pack after being cooled with a radiator or heat
exchanger.

4
8.1 Temperature Variation in Water Cooling Block

The first graph displays the change in temperature in a water cooling block over
time while a battery-powered vehicle is in operation. The y-axis displays
temperature in degrees Celsius, while the x-axis displays time in seconds. The
graph demonstrates how the temperature changes while the car drives, gently
increasing and lowering over time.

Fig. 8.1 Temperature Variation in Water Cooling Block

The battery's heating and cooling cycles when it is in use are to blame for the
temperature variations. The heat produced by the battery when current passes
through it during usage is absorbed by the water cooling block. The temperature
drops as a result of the heat being transferred from the battery to the water.
However, when the battery is utilized more, more heat is produced, and the water
cooling block's temperature rises once again.

4
8.2 Temperature Difference when Cycle is ON

The temperature differential between the battery cell and the cooling water during
the cooling cycle is seen in the second graph. The y-axis displays the temperature
differential in degrees Celsius, while the x-axis displays time in seconds. A rather
consistent temperature differential over time is seen on the graph, with occasional
slight changes.

Fig. 8.2 Temperature Difference when Cycle is ON

When the cooling cycle is active, heat from the battery is absorbed and carried
away by the water cooling block. As a result, the cooling water's temperature rises
while the battery's temperature drops. A steady temperature differential between
the two indicates that the cooling system is working effectively and the difference
in temperature between the two serves as a gauge of its efficiency.

4
8.3 Temperature Difference when Cycle is OFF

The third graph illustrates the difference in temperature between the battery cell
and the cooling water while the cooling cycle is not running. The y-axis shows the
change in temperature in degrees Celsius, while the x-axis shows time in seconds.
When the cooling cycle is switched off, the graph exhibits a dramatic increase in
temperature differential, showing that the cooling system is not in use.

Fig. 8.3 Temperature Difference when Cycle is OFF

When the cooling cycle is off, the battery relies on passive cooling methods such
as air flow rather than being actively cooled. As a result, the battery's temperature
may rise quickly, creating a significant temperature differential between it and the
cooling water. A significant temperature differential may be an indication of
ineffective thermal management of the battery, which can result in decreased
battery performance and longevity.

4
8.4 No. of Cycles vs Depth of Discharge Temperature

The fourth graph displays the correlation between the number of cycles and the
temperature at the depth of discharge in a battery-powered vehicle. The y-axis
displays the depth of discharge temperature in degrees Celsius, while the x-axis
displays the number of cycles.The graph demonstrates that the depth of discharge
temperature rises along with the number of cycles. This is due to the fact that the
battery produces heat throughout each cycle of usage, which may result in an
increase in temperature. In addition, the battery's internal resistance rises with time
and use, which might result in even greater heat production and higher
temperatures.

Fig. 8.4 No. of Cycles vs Depth of Discharge Temperature

Because high temperatures can result in decreased battery performance and

longevity, the depth of discharge temperature is an important factor in battery
thermal management. As a result, it's critical to develop an efficient thermal

4
management system to regulate the battery's temperature while it's in use,
especially as the battery experiences more usage cycles. The design of a thermal
management system that can successfully regulate the temperature of the battery
may assist ensure optimal battery performance and longevity by taking into
account the link between the number of cycles and the depth of discharge
temperature.

In general, battery cell heat regulation is an important consideration in the design

and operation of BEVs. Battery performance can be improved, battery life can be
increased, and safety risks may be avoided with efficient heat management
systems. To keep the battery cells operating within a specific temperature range,
BEV manufacturers use a combination of passive, active, and heating devices.

4
 CHAPTER 9
COST OF ESTIMATION

The cost of all the components used in this work is mentioned below in Table 2.

Table 2 - Cost of Estimation

COST IN
S. NO PRODUCT NAME
RUPEES
1 Water Pump 520
2 Arduino Board MEGA 2560 R3 1549
3 Water Cooling Block 810
4 High Temperature Hose 200
5 Radiator 1300
6 Arduino Programming Cable 39
7 Temperature Sensor 557
8 Water Tank (6 liters) 350
9 Framework Material 300
10 Radiator Hose 400
11 8mm Hose Clamp 90
12 Relay Module 200
13 Arduino Programming 2000
14 Reducer Valve 340
15 12mm Hose Clamp 20
16 12V Rechargeable Battery 572
17 8mm Pipe Nozzle 80
18 Nuts and Bolts 10

Total 9337.00

4
9.1 Product Bills

Fig. 9.1 Invoice of Water Cooling Block

5
Fig. 9.2 Invoice of Temperature Sensor

5
Fig. 9.3 Invoice of Water Pump

5
Fig. 9.4 Invoice of Arduino Components

5
 CHAPTER 10
APPLICATIONS

The application of battery cell thermal control is primarily in Battery Electric

Vehicles (BEVs), but it can also be used in other areas where batteries are used.
Here are some examples of applications of battery cell thermal control:

10.1 Electric Vehicles

BEVs rely on batteries to power the electric motor, and the batteries need to be
kept at an optimal temperature range for optimal performance, safety, and
longevity. Battery cell thermal control is essential in electric vehicles to ensure that
the battery is maintained at the right temperature range.

10.2 Hybrid Electric Vehicles

Hybrid electric vehicles (HEVs) have both a battery and an internal combustion
engine. The battery in HEVs also needs to be maintained at an optimal temperature
range for optimal performance. Battery cell thermal control is also essential in
HEVs to ensure that the battery is not damaged by high temperatures.

10.3 Renewable Energy Storage

Battery cell thermal control is used in energy storage systems that rely on batteries,
such as those used in renewable energy storage. Batteries in these systems need to
be kept at an optimal temperature range to ensure that they can store energy
effectively and have a long lifespan.

5
10.4 Portable Electronic Devices

Battery cell thermal control can also be used in portable electronic devices, such as
smartphones and laptops. The batteries in these devices can become hot during use,
and thermal control can help to prevent damage to the battery and ensure safe
operation.

In summary, battery cell thermal control is primarily used in BEVs and HEVs to
maintain the battery's optimal temperature range for optimal performance, safety,
and longevity. It can also be used in energy storage systems and portable electronic
devices to prevent battery damage and ensure safe operation.

5
 CHAPTER 11
SUMMARY & CONCLUSION

Battery cell thermal control is a crucial aspect of ensuring the safe and reliable
operation of batteries. Thermal management systems are used to regulate the
temperature of battery cells and prevent them from overheating or overcooling,
which can lead to reduced performance, decreased battery life, and even safety
hazards such as thermal runaway.

11.1 Summary

The project aimed at developing an efficient thermal control system for the battery
cells in a battery electric vehicle (BEV). The system is designed to regulate the
temperature of the battery cells, ensuring they are maintained within optimal
ranges to improve their performance, safety, and longevity.

11.2 Benefits of the Project

Enhanced battery performance and lifespan: With an efficient thermal control

system, the battery cells' temperature is regulated, ensuring they operate within
optimal ranges, increasing their lifespan, and improving their performance.

Improved safety: The thermal control system also helps prevent overheating,
reducing the risk of thermal runaway, which can lead to fires and explosions.

Better energy efficiency: A regulated battery temperature leads to improved

energy efficiency, reducing the amount of energy wasted during charging and
discharging, thereby increasing the BEV's overall range.

5
11.3 Learning from the Project

The project has highlighted the importance of thermal management systems in

BEVs. It has also emphasized the need to design and develop such systems that are
efficient, reliable, and cost-effective. Additionally, the project has demonstrated
that a well-designed thermal control system can significantly improve a BEV's
performance, safety, and lifespan.

11.4 Achievements of the Project

The project has successfully developed an efficient thermal control system for the
battery cells of a BEV. The system has been tested and proven to regulate the
temperature of the battery cells, maintaining them within optimal ranges. As a
result, the BEV's performance, safety, and lifespan have been improved.

11.5 Safety Standards of BMS

Some of the important safety standards for Battery Management System include:

IEC 62619: This standard specifies the requirements and test methods for BMS
used in electric vehicles. It covers aspects such as communication interfaces,
protection functions, and thermal management.

UL 1973: This standard provides safety requirements for BMS used in stationary
battery energy storage systems. It covers aspects such as overcurrent protection,
overvoltage protection, and cell balancing.

5
ISO 26262: This standard provides a framework for functional safety in the
automotive industry. It covers various aspects of the development process,
including hazard analysis, risk assessment, and validation.

SAE J2929: This standard provides guidelines for the functional safety of BMS
used in commercial vehicles. It covers aspects such as system architecture,
software development, and verification and validation.

IEEE 1725: This standard specifies the requirements and test methods for BMS
used in portable devices. It covers aspects such as protection against overcharging,
over discharging, and short-circuiting.

11.6 Conclusions

The development of an efficient thermal control system for battery cells in BEVs is
crucial in improving their overall performance, safety, and longevity. The project
has successfully designed and developed such a system, which has been tested and
proven to be reliable, efficient, and cost-effective. The project's achievements and
findings can be used to develop and improve thermal management systems in
future BEVs, leading to more sustainable and efficient transportation.

5
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